Steel Marvels

National Museum of Indian Cinemas, Mumbai

The “National Museum of Indian Cinemas” is located in South Mumbai – in the congested, prime and sensitive area of Pedder Road, in Mumbai. The structure comprises of lower ground floor + Ground Floor + 4 Upper Floors with mezzanine floor between 3rd and 4th floor and 4th and 5th floor + Terrace Floor.The “National Museum of Indian Cinemas” is located in South Mumbai – in the congested, prime and sensitive area of Pedder Road, in Mumbai. The structure comprises of lower ground floor + Ground Floor + 4 Upper Floors with mezzanine floor between 3rd and 4th floor and 4th and 5th floor + Terrace Floor.

Mahimtura Consultants was appointed as a principal structural design consultant on the said Project. The scope of works includes carrying out structural analysis, concept and final design, issue of construction drawings, site supervision as and when required and issuing structural stability certificate. Structural Aspect Structurally, the entire building is designed as composite steel building, as per European Code EC4 and American Code AISC 360 – 10. The composite design is opted in view of the cramped location of the project and various site constraints, architectural restrictions.

The structure is designed for combination of gravity and lateral load, as per seismic and wind load conditions, in accordance to the codal provisions. Columns are also designed as a composite element in order to achieve minimum sizing, thereby resulting in optimization. A suitable and most appropriate structural system is evolved using combined benefits of both, the concrete and steel. The structural system has been configured to overcome 1st mode torsion caused due to the shape of the building.

Span of beams varies from 8 m to 15 m and floor to height is 3.0 m to 3.8 m. By providing beams with longer spans, created column free large spaces for various areas viz:a) Auditoriums (Approx. 15 m x 22 m) b) Escalator cut outs (Approx. 5.5 m x 13 m)c) Exhibition halls (Approx. 15 m x 22 m)d) Food court (Approx 15 m x 22 m)

Salient features
A steel building with composite design shall offer an increased carpet to build up Area ratio which is beneficial to the end user. As experienced members of India’s construction industry, it our moral responsibility to encourage the building of steel structures as they are the need of tomorrow. Though the cost of construction per sq. ft. is slightly high with steel, it gets offset by the shorter project duration, better clear floor headroom and more flexibility for the end user.

Use of 355 grade steel helped in optimizing the design resulting in sleeker column look and reduced column sizes offering an increased carpet area and headroom for the client. Selection of 355 grade sections was undertaken on the basis of sections readily available in the market, from material procurement perspective.

In order to create an additional stiffness in the structure, we have ……a) RCC shear walls on all floors.b) Very strong composite columns (Structural Steel and Concrete) c) High grade concrete (M 40), High grade reinforcement steel (Fe 500) and High grade structural steel (355 Mpa).

Additional wind bracings are proposed at some selective locations. Self-supporting decking sheets are used for floor slabs as per required fire rating. Exposed steel beams are protected against fire, by providing spray vermiculite coating / treatment of 2 hours fire rating.


The versatility of steel allows infinite solutions and gives architectural freedom to the designers to create iconic landmarks for human beings to used. The use of 355 grade steel helped in optimizing the design and resulted in sleeker column section. The reduced column sizes offer increased carpet area and headroom for the Client. We could use 355 MPa and 420 Mpa, high grade steel sections for all future steel buildings, if they were made easily available in multiple sections and at reduced cost. The speed of construction of the sleeker section would definitely help the steel construction industry to grow.
Hiten Mahimtura & Sailesh Mahimtura
Directors, Mahimtura Consultants Pvt. Ltd

The contractor prepared the Quality Assurance Plan, which was reviewed by the Inspection Agency and approved by the Client and MCPL. The Client appointed an independent agency to conduct all necessary tests as per approved Quality Assurance Plan (QAP) and/or Inspection and Testing Plan (ITP) which shall typically included material identification and testing, setup inspection, weld visual inspection with relevant NDT method like radiographic (RT), ultra-sonic (UT), Magnetic particle (MT), Penetrant Test (PT) and if required for other non-destructive tests on the structural steel during various states of work starting from material procurement, material testing, weld test, qualifying the welding procedure and welders, checking fabrication and erection work and checking of fire proofing works etc.

Structural UniquenessWith large span of beams and restricted floor to floor height, beams are designed as composite beams, having shallower depths. Main elevation Glass facade of size 30 m x 40 m is supported on pre-stressed cable net. Cable net is formed by diagonally placed cables in two perpendicular directions as per elevation requirements. Cables are pre-stressed to support glass façade. Building columns are designed for pre-stress forces applied to cables.

Challenges Due to inadequate handling space at site, procurement, fabrication and testing of the structural steel was done in the contractor’s fabrication yard. The prefabricated members were then transported to site, lifted and finally erected. The steel connections are kept simple, using High Strength Friction Bolts Grip (HSFG) bolts.

Design of cable net is carried out in such a way that horizontal deflection of entire Glass façade under wind forces is well within permissible limits as per code requirements. It was a real challenge to satisfy structural requirements within architectural restrictions like spacing of columns up to 15 m and floor to floor heights are 3.0m to 3.8m.

Navi Mumbai Municipal Corporation Head Office

Fact File
Client: Navi Mumbai Municipal Corporation
Architect: Hiten Sethi Associates
Structural Consultant: Shanghvi & Associates Consultants Pvt. Ltd. ( SACPL )
Civil contractor: Ashwini Infra
Status: Completed

The recently completed office building for NMMC is an iconic building that stands apart from other structures in aesthetics, functionality and the structural design competencies associated with it. Primarily, the structure intends to be the main office building for the NMMC (Navi Mumbai Municipal Corporation) and it stands at sector 15A at CBD, Belapur. M/s Hiten Sethi Architects Pvt. Ltd were the Architects for this project and M/s SACPL – the Structural Design Consultants.

The idea of building the Navi Mumbai Municipal Corporation (NMMC) came around 2005. Prior to the present location, the site selected was in Vashi, where two existing buildings were present at the site and the NMMC wanted to transform these buildings into the NMMC headquarters. The idea was to bring all the departments under one roof.

By creating such a structure, the people of Navi Mumbai could avail better services all under one roof. However, later it was decided that a new plot at a prominent location should be selected to create the NMMC headquarters. CIDCO has always stated that Navi Mumbai is the city of the 21st century. Besides infrastructure, we required a landmark that will boast the city spirit that is evergreen. They finally settled for the current plot on which the NMMC headquarters now stands due to its strategic location.” Both geographical and topographic studies have been carried out for this iconic project.

 

The grand entrance pier is made of only five to seven columns and it is supported at the entrance with three-level high floors supported by a flat slab on top, hence there is no false ceiling involved. About 80 per cent of the slab is exposed and painted.” This project also comprises 20-m column-less office spaces on all floors. These columns are created with PT slabs. Apart from the triple height grand entrance foyer, the project features a 9-m-wide suspended glass canopy supported by only one column and has made use of a composite stone dry cladding system. Every detail has been executed with the vision that each element should have its own story to tell.

HITEN SETHI, CEO, HITEN SETHI & ASSOCIATES

 

Iconic Design
The idea was clear; the NMMC headquarters had to be an iconic structure that becomes a landmark structure for the city of Navi Mumbai. The Architect knew what they needed and hence did not want to copy or replicate any structure. They realised that features such as a dome or shell should be part of the structure.

Owing to the iconic landmark that had to be created, designing the structure was a challenge. Everything had to be of a bigger and larger volume. Post-tensioned (PT) beams and slabs have been used to achieve large column-less spaces for the office areas. Apart from this, PT span beams of 45 m are rested on column corbels and float bearings by making use of a bridge like technology and methodology to ensure structural safety in case of an earthquake.

The structure is a circular building that is 100 m in diameter and comprises a 45-m diameter triple height atrium. The Architect did not want any columns in the atrium and hence carried out a span of 45 m to cover it at a height of 22 m above ground level. In addition, interesting detailing has been carried out at the entrance with the help of spider glazing systems. The NMMC headquarters comprises three glass-reinforced concrete (GRC) domes; the mega dome at the centre has a diameter of 40 m and is positioned over the Mahasabha Hall. It has been created from structural steel framework and has been given a GRC finish. In fact, it is the largest dome in India made of GRC.

It also includes two other domes that are 12 m in diameter designed in a similar manner. These domes are positioned above the mayor and commissioner’s chambers on the fourth floor. The grand entrance pier is made of only five to seven columns and it is supported at the entrance with three-level high floors supported by a flat slab on top, hence there is no false ceiling involved. About 80 per cent of the slab is exposed and painted. This project also comprises 20-m column-less office spaces on all floors. These columns are created with PT slabs. Apart from the triple height grand entrance foyer, the project features a 9-m-wide suspended glass canopy supported by only one column and has made use of a composite stone dry cladding system. Every detail has been executed with the vision that each element should have its own story to tell.

Geometrics of the Iconic
The total construction area of the project is 2.5 lakh sq. ft. The structure has 7 levels, above the ground floor. The first, second and third floors are having the central portion as void. So, a person standing at the ground floor lobby gets an astounding view of the circular shaped outer structure with circular columns and the high ceiling of about 25m.

The fourth floor and the fifth floor are having full floor plate including the centre circular area. The roof level is 12.7m above the fifth level and in between there are intermediate part levels. The dome projects above the roof level over the inner circular area. The maximum height of the structure is 56m above the ground level. There is one basement also for the vehicle parking. The extended basement area is having a maximum size of 160m in length and 150m in width.

The foundation of the structure is done with Independent footings. The foundations are supported on rocky strata which is 7.5m below the road level. The rock formations are having a bearing capacity of 80t/m2 as recommended by the Geotech consultant. The floors are either normal beam/slab system or Flat slab system. Flat slabs with peripheral beams were used extensively in the floors. If the slab panel size is more, they were given pre-compression using post tensioning.

Normal concrete of Grade up to 40 N/mm2 (M40) is used for the structure. Two-hours fire resistance is adopted as per the NBC guide lines and the analysis is done as per the relevant IS codes. 3D models of the structures were done using the latest finite element software ETAB. The foundation and the slabs were designed using FEM software SAFE.

Structural Encounters
There are various structural engineering aspects which makes this structure unique among other office buildings.

Floor Slab at the 4th Level:
The size of the central circular floor area is 43.2m diameter. To support such a huge span, various farming methods using reinforced concrete and others like structural steel framing and pre-stressed concrete were prepared and compared. Finally, pre-stressed beams with RCC slabs were selected. PT beams with sizes of 600mm width and 1600mm depth are used to effectively transfer the huge floor loads to the supports. These were pre-stressed with bonded post tensioning methodology.

It now holds a record for the maximum span for a pre-stressed concrete beam and entered in to the Limca book of world records. Specially designed shuttering systems were used for this floor as it stands at a height of 18.25m from the ground floor level.

The Circular Dome:
The dome at the roof level is having a diameter of 43.2m and the apex point is 15 m high. Such a large size dome was conceived with structural steel framing with GRC sheeting. This Dome has been recognized as the biggest dome by Limca Book of World records. Apart from the Central dome, there are two smaller domes as well at the fifth floor. But the sizes of those are only 15m in diameter.

Major Corbels for the Floor Supports:
The central circular areas are supported on the corbels taken from the inner ring columns at the 4th and upper levels. These are 1m wide and have a depth of 1.2m- 2.2m. These allow for the natural expansion joint between the outer portion of the building and the inner circular area.

Finite element models were done to capture the stress flow patterns and it clearly shows the desired load path as expected from these elements.

Suitable bearing pads are designed in such a way to allow uniform transfer of load from beams to these corbels. They permit beam rotation at the bearing point due to deflection and also allow lateral movement. These also insulate the sound and vibration transfer between the two parts.

Seismic Design of the Structure:
Stringent norms were considered in the lateral load design of the structure, especially for seismic forces. The code prescribed values (like seismic zone) were enhanced further, considering the importance of the structure. The detailing is also done to ensure that proper ductility is available for all the main lateral load carrying elements.

As the central portion is structurally detached from the main structure, it can move separately during seismic condition. The main structure is checked and designed for the associated forces from this phenomenon.

Construction sequence analysis is done to capture the non-linear behavior of the structure when it is being casted in different stages. It is important for this structure as the loads coming on to the columns are quite large, though the no. of stages is not much.

Free Standing Columns at the Ground Level
There are some columns which are free- standing (without tie at intermediate levels) up to the fourth level slab, i.e. about 25m height from the fixed base. The sizes of the columns were fixed by considering the slenderness moments and the buckling aspect.

Structural Health Monitoring System (SHM)
Due to the large span of the central floor area, proper monitoring of the structural responses is to be observed for the service life of the structure. Keeping this as objective, strain gauges and penetrometer were planted in the concrete at these levels to check whether any excessive deflection is happening at these levels.

Further, it is planned to have much more sophisticated tools to measure the accelerations and vibrations also. These facilities will provide the building management team, the real-time information on the building movements and characteristics to effectively service the structure during its life time.

Construction Methodology and Quality Control
High standard construction methodologies were used throughout the full construction phase of the structure. Stringent quality control norms were also followed. At the super structure, special shuttering methods were adopted for the fourth floor. The erection of the central dome also demanded precision formworks. Pour sequence for the casting of this structure also is an important aspect because of the parameters like large spans, pre-stressing, corbels, expansion joint etc.

 

When we were assigned the structural design of this project, which is only about 2.5L sq. ft., we never imagined that this one to be turned out as a landmark project in the Navi Mumbai area with such an iconic proportion. The entire project duration of about 4 years was mixed with many challenges, in the structural designs as well as in the site execution. The complexities of the structure are obvious in the geometry itself and the hardships which we had gone through in materializing the vision of the Architectural intend has finally become fruitful in all aspects, which in fact is the true reward for any professional.
JITESH PATEL, Principal Engineer, SACPL

 

Materials Used
In this project, composite marble with a six-side sealed stone has been utilized for exterior dry cladding.

The support system for dry cladding has also been used with the help of aluminium-based technology. All decorative elements in column cladding, cornices and domes, have been created by GRC. For the triple height atrium, we have used a metal ceiling.

Composite marble with higher aesthetic value has also been used in the entrance foyer and upper floors. For all glazed areas, DGU is used and lustre paint has been applied on walls. Acrylic emulsions are applied to ceilings instead of plastic emulsions for the interiors.

Epitome of efficiency
The building has been registered with LEED-IGBC for certification and aims to receive the Gold rating for this project. The project also features a rainwater harvesting system with 13 groundwater recharge pits for harvesting surface rainwater and collection tank for terrace rainwater. A biogas plant has also been constructed to generate cooking gas for the project. In addition, a sewage treatment plant of 0.150 mld along with a water purification system has been installed at the premises.

The treated water is used for cooling towers, flushing and gardening. Sustainable materials in the form of GRC and manufactured stone have been used for dry cladding. This ensures a ventilated facade and keeps interiors cooler. The glass does not overpower the boldness of the structure; and a minimal percentage of glass in and around the structure has been kept. Apart from this, water-cooled chillers have also been utilized in the project. The cost of the project is about Rs 180 crore and the payback period is seven to eight years. The final result: a green success!

Amararaja Growth Corridor, Chittoor

Amararaja Group of Companies proposed to construct a large Industrial Hub at Mordhanpalli in Chittoor District of Andhra Pradesh on the Chennai-Bangalore NH (old Madras Corridor). The proposed hub is planned in an area of about 510 acres and the master plan prepared in this regard has factory zones, residential zones, IT zones etc. The total extent of the land is 510acres & the development is planned in a phase wise manner.

The battery plant occupies 75 acres in the complex. It comprises of four main factories, MVRLA, ABD, TUBULAR and PLASTIC PLANT which will produce industrial batteries. The factory buildings are oriented in the north south direction. A complex network of services and utilities are required to support the production area.

Lighting Effects
Daylight is harnessed through sky light roofing to the fullest potential for the indoor working during day time to the factory level day lighting. Poly carbonate single wall sheets are planned horizontally on the peripheral wall sheeting above 6m level and sky lighting 5 per cent on roof area. Skylights provisions are endowing with polycarbonate sheets at 5 per cent of roof and wall lights in wall area to increase natural lighting. Roof monitor is provided on roof for all buildings.

Aesthetics and Safety
Two coats of oil paint zinc chromate (anti-corrosive) primer and two coats of synthetic enamel oil paint on all built up sections. Canopy with projection of 3000mm on either side to avoid rainwater coming in doors. Stub post of 450mm height from roof level is considered on roof to hold fall protection. Platform for exhaust fan / AHU is provided.

The building is provided with trapezoidal wall cladding which makes its appearance aesthetically appealing enough from all the sides. The roof area is fitted with solar panels currently in MVRLA plant and ABD plant which produces 13.2 and 13.1 megawatts electricity respectively.

The factories are well ventilated with windows at two levels. The first level is below (2.4m) & at second level is at 4.2m with louvers for ventilation throughout the plant. This design is provided for better comfort for the persons working inside the plant.

Structural Aspects
All buildings are designed as per IS 456: 2000 & IS 800: 2007 codes. All the live, dead and wind loads are taken as per IS 875 – Part 1,2 & 3 and seismic loads as per IS 1893 Standards.

Structural members comprise of RCC column with steel roofing members. RCC frame includes the isolated open foundation, plinth, lintel beam, columns, column bracket and crane gantry. Isolated open foundation implemented based on the higher safe bearing capacity. Steel frame includes the rigid castellated portal frames, Jack beam, Columns, wind columns along edge bay.

Roof framings are designed using conventional method as A – type and mono-slope. Castellated frames are formed from readily available I -Section and it is used to reduce weight and to attain required design depth. Jack beams are designed in such a way to support the castellated frames and to get maximum internal free space. Secondary structural framing includes purlins, girts, eave struts, wind bracing, flange bracing, base angles, clips and other miscellaneous structural parts. All purlin and girts are cold form members. Suitable wind bracing and sag rod are considered at time of design to grant the structural stability.

All buildings are covered with Lloyds sandwich panel of 30mm thick to offer a rapid coverage and swift weatherproof building envelope to give a high-performance building which will maximize the service life and reduce maintenance costs.

Longitudinal connecting beams and necessary pipe rack supporting arrangements are provided as required in building. Gutters and downspouts are adequately designed for all buildings to deliver an effective roof drainage system. All rain water header pipes encompass FRP coating and are made of PVC Pipe. The foundation anchor bolts and connection bolts are designed for a grade 8.8 and 10.9 respectively as per IS standards.

All buildings are designed as per IS 456: 2000 & IS 800: 2007 codes. All the live, dead and wind loads are taken as per IS 875 – Part 1, 2 & 3 and seismic loads as per IS 1893 Standards. Structural members comprise of RCC column with steel roofing members. RCC frame includes the isolated open foundation, plinth, lintel beam, columns, column bracket and crane gantry. Isolated open foundation implemented based on the higher safe bearing capacity. Steel frame includes the rigid castellated portal frames, jack beam, columns, wind columns along edge bay. Roof framings are designed using conventional method as A-type and mono-slope. Castellated frames are formed from readily available I-Section and it is used to reduce weight and to attain required design depth. Jack beams are designed in such a way to support the castellated frames and to get maximum internal free space.

C.N. SRINIVASAN, MD,
C.R. Narayana Rao (Consultants) Pvt. Ltd.

Global Training Center, Capgemini, Hinjewadi

The program brief was to build a campus to house a trainee population of 2000 and train them after their induction into the company and thus transit them to various locations around the world , the training block thus becomes the fulcrum of the project and the company acting as an incubatory facility from where they migrate to the development block and the other amenities were laid out to complement these two main facilities, the customer experience centre is to impart an unique experience to the prestigious clientele of the company.

Situated at
The project is prominently located in the IT Hub of Pune, Hinjewadi an SEZ Zone. The project location serves the likes of Cognizant Technologies, Ascendas also being among DSP Design’s marquee clientele. Owing to the wild slopes in the site the design team analysis led to the understanding that around 40% of the site was rendered unusable and unsuitable. Apart from their study of the site, enabled them to understand and identify a unique and naturally formed landscaped underbelly which was well and truly worthy of a design exploration that enabled to execute the design to a unique dimension.

Design Style
It is an environmentally friendly, sustainably performing facility, which imbibes a deep sense of behavioral elements into the design making, and has a lot of interactive spaces around and within the building envelope. Working the flow chart made the design team really understand the flow and interfacing of blocks with each other, the patch diagram made them understand the flow between the different user blocks, thus the development blocks were strategically placed in the front, the experience centre was sandwiched between the DB and TCEC, the amenities were set back inside all these spaces were catalyzed by the event space which held and wove all these spaces together.

Structural Essence
The structural elements of the canopy which by itself covers approximately half an acre area, which includes the training block, cafeteria and amphitheater, acts as a grand umbrella that imparts a promenade like feel to the entire campus. The structural elements weave the blocks around an event space, which is landscaped bowl, which in turn houses interesting elements like the amphitheater and play courts.

Process
The natural contour became the generator in stacking the blocks, to optimize on cutting and filling and to house 2000 cars 4 levels of car-parking floors were introduced into the contours, the podium became the platform to weave all the main blocks and strategically offer views towards the landscaped underbelly the amenity blocks were placed to experience the landscaped bowl , the service apartment which is a boarding facility is placed on the highest contour point to get a unhindered view of the reserve forest and greens beyond.

Development-Block: The DB prototype has two types of iteration the structure and the massing is typical of each other, the height varies with respect to each variant, which again is a result of the no. of inhabitants, the first variant is a G+14 structure and the 2nd variant is G+7 structure.

The blocks were placed in such a manner as to create a lot of positive spaces around each other. The podium was to act as a landscaped promenade which was to connect all the blocks like an extended street. The inter-connective bridges apart from acting as connecting elements between the blocks adds a micro urban setting and feel to the whole cluster. When one arrives at the roundabout to enter the campus the DB 01 catches the imagination of the visitors owing to its sheer volume, it is surrounded by shorter buildings which interconnects with the other blocks creating a micro urban set up around the cluster. The building mass is intentionally lifted upon stilts to create a promenade effect and also to link all the blocks through landscaped greens which is accessible and turns out to be like a town square which is shaded and buffered with green.

Training Block: a single prototype of the training block was to house a population of 500 trainees from diverse backgrounds, intentionally the blocks were laid out in a manner where positive outdoor spaces will be shaded and act as a promenade to enable interaction amongst trainees.

Architecturally the TCEC blocks were perceived as a single block, which was to be brought together by a grand umbrella towering the 4 training blocks. The canopy was to offer a grand sense of arrival apart from making a bold architectural statement. At the ground level, all these blocks were to connect with each other through the landscape podium garden, the garden, the connection being established by raising the blocks on stilts.

Amenities and Landscape: The amenity blocks were scattered around the natural landscaped bowl the cafeteria blocks were placed in a manner such that it acquires an unhindered view towards the landscaped bowl, while the service apartment blocks got unhindered views of the reserve forest ahead. The blocks despite being scattered across the landscape bowl were interestingly brought together by the grand connecting chatri which offers shade to spill out space around the cafeteria blocks and clubhouse. The service apartments are scooped rectangular block with lots of breakout terraces at various levels offering interactive spaces.

Steel usage
Combinations of ISMBs and ISMCs were used. Unitized assembly technique was used, especially integrating with ACP cladding and galvalume cladding that come as panels, which are then installed and sealed with gaskets. The unitized design of the system is a major challenge. The inward slope and the panel subdivisions were critical aspects of the design; BIM was deployed exclusively to overcome this challenge.

Fact File
Function: Commercial
Architect: DSP Design Associates Pvt. Ltd.
Design Consultant: Vastech Consultants
Executing Team: L&T EDRC
Tonnage: 150 MT
Status: Completed

Noamundi, Jharkhand

Tata Structura has opened a floodgate of opportunities for architects and structural engineers. The brand has created unprecedented possibilities with innovative solutions. The mass housing project for the Raw Material Division of SAIL in Gua, Jharkhand, is an instance where Tata Structura has been able to make a difference not only in the construction process, but, also in the lives of the people of that region. The project was assigned to the structural consultants Sinha & Associates, Kolkata. The contractor was Lloyd Insulations (India) Limited, Kolkata and BSD Enterprise, Kolkata was the fabricator of the project.

The project was completed successfully and brought the blessings of secure shelter to the people in Noamundi. The modern structural design employed in the project represents the remarkable progress in the world of construction in India. Yet again, Tata Structura established steel as the preferred material for building tomorrow’s India across all sections in our society.

In all, 218 MT of Tata Structura hollow sections were used in the construction of these residential buildings. A total of 27 buildings were constructed and 8 MT of hollow sections were used in the construction of each of these structures. It took six to eight months of well-planned construction work to complete the entire project. The extraordinary strength and flexibility of Tata Structura made it the preferred choice for constructing the houses which demanded that they be sturdy and last really long.

Fact File
Client: Steel Authority of India
Consultant: Sinha & Associates
Steel Supplier: Tata Structura
Tonnage: 218 MT
Status: Completed

Biz Life Noida

In the present era of rapid globalization, swelled and prolifying demands for quality, innovative and worthy lifestyle are at a high. In order to cater to these requirements, Proplarity Biz Life emerged out as one and only such milestone that is set to achieve all objectives of providing quality infrastructure with energy efficiency in ecological friendly environment.

Proplarity Group, a leading real estate giant, launched its new project in Noida, spread across nearly 5 acres. Biz Life is the new commercial project in the heart of Noida spread across 5 acres of land offering office space, retail shops, IT/ITES space at sector 62 Noida, a semi-residential and commercial sector. It offers office spaces starting from 200 sq. ft.

Through this project, Proplarity offers multiple options of investment which includes lockable spaces, virtual spaces, fully furnished office spaces, semi furnished office spaces, zoning is done in such a manner that it differentiates the basic zones like retail, public interaction spaces, congregational spaces, food and cuisine activities and offices without interfering into the function of other zones.

A blend of contemporary and eco-friendly structure design, it is a perfect amalgamation of green areas and plush interiors blend together to offer world-class experience. Initially conceived as a commercial center, finally developed into a commercial cum residential plaza. The project will eventually offer space ranging from 150. sq. ft. to 5000 sq. ft. having multiple options such as local space, virtual space along with resistance with 5-star luxury standards.

Main Features

  • Furnished and unfurnished office space
  • Provision of residential space in same building complex
  • Recreational facilities like bowling alley, cinema, club, banquet hall
  • Convenient shopping, restaurant, high street shopping
  • Quality infrastructure with energy efficiency in eco- friendly atmosphere

Aesthetics of the Exclusive
Biz Life Plaza set in a relatively complex plan and curved out line, both, in elevation and plan with setback at various labels present a stemming and at the same term. It has an aesthetically pleasing view and when completed, it shall be one of the first steel residential cum commercial complex with a dedicated objective of setting a benchmark for other similar building in NCR areas.

Describing the Unique
The building is a multi-tower type structure. The building has two basement levels, above which stands the rest commercial floors with 6500 sq. mtr. each up to 6th floor. Above the 6th floor stands two tower, both rising to 30 floors. The helipad is located on the top of Tower A.

Structural Efficiency
The units of offices are well integrated, such that the floor plan is unsymmetrical with respect to the vertical axis as well as the horizontal axis. Therefore, as a concept, a frame tube structure system analogy has been proposed to control lateral displacements due to lateral loads. Shear wall have been introduced in a core, and few other areas about the horizontal axis.

Steel-concrete composite framing has been chosen for office area and podium area which result in smaller column sizes as compared to a conventional RCC column. Steel-concrete composite systems have become quite popular in recent times because of their advantage against conventional construction. Composite construction combine the better properties of both i.e. concrete and steel and result in speedy construction with a possibility of working on a parallel front.

Typical main framing was placed in a grid size of 8m x 8m with cross beam spaced at approx. 4th center, the secondary beam spacing being dictated by loading intensity and type/class or prefilled deck shaking being deployed for the project. Above ground, the superstructure consists of composite steel structural system, both, for floor and column. Whereas ground floor and lower upper basements are in RCC, with the floor slab being conventional RCC flat slab with drop panels.

For achieving optimum structure efficiency, the structure grid spacing in the basement level have been adopted in all basement levels and continuing in the superstructure area of the tower and the retail areas. This negates the necessity of expensive transfer structure only on some portion to utilize the clear area of drive-way in parking area.

Transfer trusses are occurring at 5th and 6th floor level to provide spacious open hall for auditorium at floor and to create space with minimum number of column for banquet hall from 3rd to 5th floor. The transfer trusses pass in the building load from the upper floating column down on the main column at lower level.

We believe in coming-up with unique and pioneering projects which stand true to the standards of world-class. The design of Bizlife was conceived as an iconic building to be projected as a landmark in Noida. In this building, steel is used right from the ground floor onwards in entire building, as it assists in faster and accurate construction with best earthquake resistant design. Fabricated I sections of special grade mild steel sections are used in the making of this project.

SATYENDRA TOMAR
Managing Director, Proplarity Infratech Pvt. Ltd.

 

Special Structural Elements
Differential shortening of columns:
All concrete element subjected to axial stresses undergo axial deformations during both, the short term and the long term, due to elastic deformation, concrete shrinkage, and creep. These effects, whilst typically negligible on shorter buildings, can become significant in tall structures, particularly where stiff elements, such as outriggers connect the central core and the perimeter column. This is due to the potentially significant stress differential that exists between these two vertical elements. The effects of short and long term column shortening will be considered in the design of the outrigger elements.

Movement Joint
Movement joints are required to accommodate the effects of changes in temperature, and hence, to control movements to below excessive levels. At movement joint locations, a complete discontinuity of the structure is achieved and so placement of joints at potential contract phasing boundaries is advantageous. This has been taken into consideration when selecting joint locations for this project. Expansion joint are provided in the extended basement between adjacent blocks filling the codal requirements.

In vertical plan, the structure system comprise of OMRF + steel bracing + ductile shear wall which is required to center relatively high seismic force, lateral force, and displacement within prescribed limit in the shear walls are kept to minimum, being provided generally in lift areas or close to lift areas.

Structural USP
Extensive use of composite construction concept is used to economize the structure steel. There is a reduced execution time required for the project due to composite construction methodology. The structural concept used in this project is a pioneer in composite construction in the entire NCR area. The project went through a complex and protracted evolution process in which various options, both, in space and layout arising out of functional changes, as well as structural concepts which finally culminated in a breath-taking look in composite construction.

Coming to terms with evolution demands for substantial change, frequently posed a challenge for structural consultant to successfully deliver the result to the satisfaction of all parties concerned including client, architect, fabricator and the contractor. However, impressing the outcome, the overall experience has been quite inspiring for structural consultants.

A part from the ever attractive cutting down of construction time, the steel frame system adopted in this building permits served interesting design features which would not be normally possible by using traditional building methods in concrete. The building was originally conceived in concrete, but, with forceful persuasion emphasizing the above-mentioned selling points in favor of steel vis-à-vis composite construction. The owner decided to choose composite construction for this building project.
HARIOM GERA, Director, Constructure Designs Pvt. Ltd.

Fact File
Function: Commercial
Client: Proplarity Infratech Pvt. Ltd.
Architect: Design Forum of Architects
Structural Consultant: Constructure Design Pvt. Ltd.
Steel Tonnage: 7000 tonnes
Current Status: Ongoing

VIZAG INTEGRATED PASSENGER TERMINAL

Visakhapatnam Airport is the largest and one of the busiest airports in the state of Andhra Pradesh. The Airport is located about 7 KM from the city of Visakhapatnam popularly known as Vizag. The airport began its civilian operations in 1981 with a couple of flights per day. However, today it is the busiest Airport in the state handling both, international and domestic flights.

In 2009, due to increasing air traffic, the Airports Authority of India (AAI) constructed a new passenger terminal at the airport and converted the old terminal into a cargo complex. The new terminal handles both, the international and domestic passengers. The new integrated passenger terminal covers an area of 20400 sq. meters and can handle 300 passengers on arrival and 700 passengers on departure at a time.

Massive Roofing
The new integrated passenger terminal is covered by a massive steel roof. The terminal roof structure consists of arched and flat steel 3D triangular space truss made of circular steel tubes and mounted on RCC columns. The roof structure is divided in to 3 main sections which are mounted at 3 different elevations. The roof truss facing the runway is mounted at a height of 14.72m. The city side roof truss us mounted at a height of 4.94m.

The roof truss between the runway-side and city side canopy is mounted at a height of 11.42m. The depth of the space truss in the runway-side and the middle section is 2m whereas the depth of the roof truss at the city side is 1.061m. The maximum length of the roof structure is 182m and extends to about 100m from the runway side to city side.

Best Out of Left-Over
On 12th October 2014, a very severe cyclonic storm Hudhud made landfall in the coast of Andhra Pradesh over Visakhapatnam. During landfall, the cyclone had a maximum sustained wind speed of 180 kmph. The cyclone also caused heavy rainfall with strong gale winds leading to large scale structural damage over Visakhapatnam and along the cost of Northern Andhra Pradesh and adjoining Orissa. The strong gale winds caused heavy damage to the terminal roof and adjoining buildings.

Although the terminal roof was designed for such heavy wind pressures, the entire roofing sheet of the terminal was blown away. This was largely because the roof at the time was made of thin GI roofing sheets and the connections between the roofing sheet and the roof purlins were not designed or sufficiently enough to resist the extreme gale forces. As a result, the connection between the roofing sheet and the purlins failed and sheets was blown off. Subsequently, the roof insulation, false ceiling and HVAC installments got exposed to very severe wind and rain causing these items to be completely blown away. However, once the roofing sheet failed and was blown off, the wind fore on the roof truss reduced considerably and therefore the roof truss was largely intact and undamaged.

Since the terminal roof frame was virtually damaged and replacing the entire roofing frame will take considerable amount of time, the authorities decided to install a new roofing sheet on the existing roof truss. Also, replacing the roof truss will severely affect the daily operations at the airport during the construction and will leave most part of the terminal exposed to the elements of nature for several weeks or months.

Hence, the best viable option was to make use of the existing frame work. However, to do so, the roof frame should be verified for its strength and stability. Further the region being cyclone prone, the roof should be checked and certified to resist cyclonic winds and to satisfy functional requirements and ensure structural integrity of the structure as envisaged in the applicable safety standards.

Engineers at Mission
IIT Madras was tasked with the responsibility of certifying the structural integrity and safety of the existing steel roof frame. The role of Marvel in this project was to assist IIT Madras by doing an independent analysis and design verification of the roof frame with updated loads as per the latest Indian standards.

Marvels’ engineering team did a rigorous and thorough analysis of all the steel sections, their joints and connections and certified the safety of the existing roof frame for both, strength and stability for these updated loading conditions. A team from IIT Madras also visited the site and did a thorough inspection of the structural integrity of the roof frame and their joints and connections. Marvel also submitted a set of recommendations and design upgrades for better performance of the roofing system during high wind loads.

Marvel’s engineering team modeled the entire roofing system in STAAD Pro and did an independent analysis of the steel truss system. For the refurbished terminal roof, AAI proposed the use of rock wool insulated sandwich roof panel instead of previously used thin walled roofing sheets. These panels were heavier and sturdier than the roofing sheets used and their extra weight had to be incorporated in to the analysis. Further, taking in to account of the topography of the Airport site, the roof frame was analyzed for a design wind speed of 192 kmph.

ICONIC TOWER, KOLKATA

Thinking Terminology
While a lot of sketches and initial drawings were worked upon to develop what is today the final design, the initial thought process was to create something out of the box, which is not just unusual in aesthetics as a landmark structure, but, also a structural marvel, in its own way. The initial concept and sketches were inspired by the elliptical form crowned with a revolving restaurant immaculately, giving a visual of the entire city, and also forming a spectacular living sculpture for all the admirers driving along.

Steeling Big
Steel was selected as one of the major part of the building material – in fact the core ingredient – as steel is found to be one of the most flexible, yet, very sturdy materials available on planet earth. It is by far used for every type of construction activity since centuries now.

With the currently available technique and technology, steel is evolved from a mere use of it as reinforcement – today steel structures have got in vogue and the design ideas are limitless with steel. Steel not only gives one the opportunity to design big, design different but enables one to think variety of forms and shapes.

Stainless steel is a boon to the real-estate / construction industry – and is also being considered use as reinforcement, to enable a structure to last more centuries without having an issue of rusted / corroded reinforcement bars. Facades with a variety of finish and texture possibilities have welcomed steel as a permanent and maintenance free material; It goes without saying that Steel is getting best out of me, while I persevere to get the best out of Steel. Me & Steel are sure to go a long way!”

PREM NATH, Principal, Prem Nath and Associates

 

Iconic Features
This challenge was upturned into an elegantly standing 129m tall tower with, covering 130,000 sq. mtrs. of construction area. The construct is deliberated such that all the appendages complement each other, and yet, celebrating its identity and function uniquely.

The central core forms the spinal cord of the structure, supporting vertical access to all floors along with all frequented services. Employees, visitors, attendees, delegates, business travelers and shopping enthusiasts all are received, at their relevant points, uninterrupted and escorted to their destinations.

Employees enter at ground floor into a large lobby, guided to their office through the central core that reaches out to the top most floors. The offices are allocated on 22 floors variant in size, with 1,000,000 sq. ft. area and forming the elliptical form in elevation. Each open span floor has 3m cantilevers at the corners enhancing the elevation geometry and alternating as the refuge areas linked with fire stairways, on all floors.

Business travelers and tourists seeking luxurious hospitality are received at the separate hotel entrance, accommodating 95 hotel rooms and 5 suites from 1st to 5th floors, providing a 5-star service, through their common kitchen on the ground floor. The Business Club on the 3rd storey forms a convention pedestal for all the business conferences, meeting and celebrations. Also, encouraging health enthusiasts inhabiting the building, to rejuvenate at the health spa, gym overlooking the swimming pool, also connected to business club, office, hotel and recreation vicinity.

The shopping fanatics enjoy their shopping experience in 90,000 sq. ft. retail souk, overlooking 3 shopping floors through the entrance atrium and traversing vertically through the escalators towards the food court and recreation areas on the 4th and 5th floor, creating a family fun destination. The food court simultaneously serves both the shopping and cinema audiences.

The 1050 box office viewers are entertained in the multiplex on the 4th and 5th storey, through three 300 pax. capacity big screen and one 150 pax. mini theatre, allowing express entries from the parking areas.

The parking is accommodated in three fractions, one, puzzle parking with 1200 cars; two, 4 basement floors with 800 cars; combined to total of 2000 covered parking. Additional 100 open car parks are given on the ground floor for visitors. The service areas are contained in the 30 per cent of basement floor, serving all the sections of the financial hub.

Last but not the least, the foodies are brought to thrill through the 2 capsule lifts, reaching to the top deck on the 27th floor, hosting semi indoor events on 30,000 sq. ft. terrace. Besides adding to the amusement, a revolving restaurant is crowned on top, giving a beautiful view of the entire city, along with a unique dining experience.

Iconic Geometrics
The structure is curvilinear yet symmetrical, creating the right structural as well as architectural balance – that is how simply one can describe the geometrics of this structure. The building expanse 110 m x 44 m, on the site, devising it with a central core. The structure is pertinently subdivided into 11 x 11 m square grid, forming 11 x 4 bays, with flat post tensioned slabs, eliminating the huge beams, availing the users ease in servicing and clear height of 2.7 to 3 m, below false ceiling.

The edifice being employed for integrated offices, business club and recreation hub, a composite structural system is being proposed, having steel section cores and R.C.C. encasing, being explored extensively to limit column size and give 10 m clear span, suiting the interior workstation module of 1.5 to 2.5 m, also accommodating effortless parking space for 6 cars in a bay.

The square grid system, along with simple conventional symmetrical design in M50 grade concrete, takes care of the seismic activities; as New town is situated in Moderate – Zone 3. The structure is kept trouble-free promising, ease in execution and stability, without any acrobatics, yet appealing and leaving an iconic reference for the identity of New Town Financial Hub Various architectural as well as structural design software used. The project is currently under development and is expected to be completed within a period of 30 to 36 months.

Experience
Each of the project is a new learning experience, this one enabled the team to think out-of-the-box and strive to do more in terms of design aesthetics, architecture and structural design or detailing.

Fact File:
Function: Commercial
Client: WIDCO
Architect: Prem Nath& Associates
Consultant: Prem Nath& Associates
Tonnage: 16,000 Tonnes
Status: Concept Development

Bosch Skywalk, Bangalore

The Bosch Campus at Adugodi Bangalore is separated by a link road between the north and south campus. Due to the heavy traffic on this road, the clients were facing lot of problems for the staff to cross over for the day-to-day activities, and the safety and security of the staff was being compromised. Bosch India Pvt. Ltd. appointed Innotech Engineering Consult Pvt. Ltd. to structurally design an elevated walkway crossing over the link road for ease of their pedestrian movement for the day-to-day work between the two campuses.

Initially, the staff members had to park their cars in the parking lot and walk across the busy road to their office. It was not only time consuming, but, hazardous too. The elevated walkway was conceptualised and designed by Innotech Engineering Consult India (P) Ltd, and Vyshakh Building Solutions Pvt Ltd were the appointed contractors for the same. Synergy Property Development Service was awarded the task of constructing a skywalk right across the busy road to provide office goers with a safe route to cross the road and reach their offices.

Structure
The structural concept was of space truss in segments to assemble the structure at site with cranes and bolts. The proposed walkway was 2.5m in width and 25.50m clear span with the foundations on either side of the campus. The clear height below the walkway was mandated to 5.5m above the road for fire truck and other transport vehicles movement. Innotech designed the structure in structural steel using square hollow sections of 100x100x5mm and 91.5×91.5×4.5mm for making it aesthetically pleasing.

The bridge was designed as space truss to use the efficiency of space truss system and optimise the cost. The floor was done using chequered plates and the roof cover using metal deck sheet. The two staircases on either side of the campus were designed using ISMC sections with chequered plates for the threads and risers.
Sections. The span was 25 metres and the cantilever bridge demanded special grade hollow sections. Fortunately, Tata Structura found the solution – with its YST 310 grade of structural. The chemical properties and tensile strength of the special grade met the requirements of such a structure which allowed 25 metres of the walkway to be suspended across the road.

A total of 65 tonnes of Tata Structura was used and the cost of the project was 7.0 million INR and was completed in a total span of 70 days including the designs, fabrication, erection and taking all necessary statutory approval from the concerned authorities.

 

“The main challenge faced in the execution of the elevated walkway was the fabrication & erection of the 25.5m span on the existing heavy traffic road and for this the design was made with connection in parts of 6m so that the same could be fabricated in the fabrication yard and transported without hindrances.”
T. S. GURURAJ
Chairman, Innotech Engineers Consult Pvt. Ltd.

 

Challenges
The main challenge faced in the execution of the elevated walkway was the fabrication and erection of the 25.5m span on the existing heavy traffic road, and for this, the design was made with connection in parts of 6m so that the same could be fabricated in the fabrication yard and transported without hindrances, these part were than assembled in the campus for a total span of 18m with all connection detail connect the same to the end bays having cantilever of 4.5m and 3m on either side of the columns supporting the same thereby not disturbing the traffic movement.

“For a decade now, Tata Structura steel hollow sections has continued to open up new possibilities in construction by encouraging out-of-the-box thinking and applications. The flexible, versatile, design friendly Tata Structura has time and again proven its worth as the ultimate innovative solution to complex problems. One such project was the creation of Bosch Skywalk at MLCP Campus in Bengaluru. Initially, staff members had to park their cars in the parking lot and walk across the busy road to their office. It was not only time consuming, but, hazardous too.”

VINEET SARAF
CMS Tubes, Tata Steel Ltd

Highlight
It was pre-fabricated and there was absolutely no disruption on the road while it was being erected. All it took was one night to install – easy availability of the requisite sizes simplified the job.

The highlight of the system is that entire erection across the road was completed with all safety precautions in just 5 hours.

Specifications
Total quantity of hollow sections used: 65 tonnes
Members:

  • 50 X 50 X 3.6
  • 91.5 X 91.5 X 4.5
  • 100 X 100 X 5
  • 50NB Pipe: TATA Circular
  • SHS: 25 X 25 X 3

 

Fact File

  • Client: Bosch India Pvt. Ltd.
  • Structural Consultant:
  • Innotech Engineering Consult India (P) Ltd
  • Contractor: Vyshakh Building Solutions Pvt Ltd
  • Steel Supplier: Tata Structura
  • Steel Tonnage: 65 tonnes

Sri Sathya Sai Sanjeevani Hospital, Ballabhgarh

Sri Sathya Sai Sanjeevani Hospital is the proposed super-speciality heart centre for children located at Ballabhgarh, Delhi-Mathura Road. The proposed building is G+2 structure with the provision of one future floor. The proposed built-up area is approximately 1,47,300 sq. ft. This multispecialty hospital will offer high quality healthcare services with numerous OTs, ICUs, with modern technology and advancement in heart care.

It is a complex heart shaped building having unsymmetrical plan. The structure is envisaged as a steel-concrete hybrid structure with substructure up to the plinth level in concrete and superstructure in structural steel.

Unanimously Steel
Since it is a fast-track project with time bound completion and due to the low soil bearing capacity reported at site, structural steel was the unanimous choice. Being a light and high strength material, structural steel offers great degree of flexibility and sturdy behaviour.

Structural Geometrics
The primary frame of the building comprises of special moment resisting steel beam-columns frame with cross bracings in vertical plane at suitable locations to resist the lateral force due to earthquake and wind. The floor system comprises of steel beam and joist with concrete slab over profiled metal deck sheet. The composite action of steel and concrete is utilised to optimise beam and joist design. Composite design helps in reducing the size of section, controlling deflection and achieving economy. Shear studs are placed at top of steel sections to transfer the shear force from slab to achieve composite behaviour.

The total design lateral forces are resisted by the columns-beam frames and bracings in proportion to their lateral stiffness at all the floor levels. Hollow tubular sections are preferred for cross bracing due to slenderness benefits resulting from higher radius of gyration. Moment resisting connections are considered for column-beam junction for rigid and stable behaviour and being lighter.

Steel columns are analysed as pinned at top of RC pedestal and support reaction at that location were considered for substructure design to make the substructure lighter. Through rigorous analysis and design iterations, the structural stability was ensured while satisfying the budgetary constraints as well as time constraints. Fire rating for the steel structure was ensured by the means of vermiculite coating used. All wall panels (external and internal) are Schnell wall panels, with 170mm thick.


“With increased use of steel sections as primary members in buildings including high rise commercial and other usage, a fast track hospital project is a challenge of design. The plan shape resembling human heart required skills to control the dynamic behaviour. Our design team of Er. Nitesh Agrawal, Er. Anisha Annee & Joby Joseph made it possible to deliver the entire design in about a month’s time. Concrete floor over metal deck connected to steel beams with shear studs helped economy of design through composite action. Fire resistance of main frame is achieved through vermiculite. In all a little more than 145000 sq. ft. built up area has been designed with less than 850MT steel sections. Integration of Schnell Walls with steel sections by Synergy team is sure to produce an excellent building”.
Er. (DR.) ABHAY GUPTA
Director, Skeleton Consultants Pvt. Ltd.

Steel Sections
The steel column-beam frame, having plate fabricated I section as well as all connection plates, are made of high strength steel having yield strength of 345MPa confirming to IS-2062. Hollow tubular sections are considered for cross bracings having yield strength of 310MPa.

Challenges
There were quite a few complexities involved while designing this project. The shape of the building is heart shaped owing to which stress gets concentrated at the corner bend which results in rotational dynamic mode shape. Cross bracings at several locations were provided in line with architectural features to control the rotational mode and deflections.

Due to low soil bearing capacity, site located in seismic zone IV and being a hospital building with importance factor 1.5, primary concern was to keep the weight of superstructure light. The connection of steel columns and pedestals are designed as hinged and composite action of steel beam & concrete slab is utilised to make the foundations lighter.

Salient Features

  • Heart shaped plan: Unsymmetrical in mass and stiffness
  • Curved periphery
  • Building located in earthquake zone-IV with IF =1.5
  • Composite design of beams and RC slab with proper shear studs anchorage
  • Use of light weight Schnell

 

FACT FILE
Client: Sri Sathya Sai Charitable Trust
Architect: Ravi Associates
Structural Consultant: Skeleton Consultants P. Ltd.
Turnkey Contractor: Synergy Thrislington
Proof Consultant: Sterling Engineering
Steel Tonnage: 1000 MT (approx.)